The purpose of this thesis has been to investigate the potential implementation of structural optimization
software in the product development process at the department of engine development at Volvo Car
Corporation. This has been carried out by performing two trial cases of optimization on two different
base engine components. The models have been created in ANSA and solved with ABAQUS and
TOSCA.
The first trial case was of a simpler nature and involved a smaller component inside the bedplate. Its
purpose was mainly to bring knowledge about FE-modelling and optimization, which it fulfilled. The
second trial case was more complex, and aimed to find the optimal material distribution on the engine
block’s exterior surface in order to increase the first eigenfrequency of the component. It succeeded in
the sense that it increased the eigenfrequency, but the optimized topology does not contain rib-like
structures to a large extent, as was hoped. Rather, the majority of the element are spread thinly over
the entire surface.
The ultimate conclusion that can be drawn from the results is that it is complicated to implement the
use of structural optimization software on larger base engine components. Optimization is better suited
for more isolated components of smaller size, with a limited number of load cases that are clearly
defined. This would give the optimization solver a better chance to find an improved structure. It would
also limit the need for simplifications and therefore allow for greater confidence in the FE-model and
in turn the optimization results. The findings in this thesis does not completely reject the potential
implementation of structural optimization software in the product development phase, but does show
that structural optimization is not without its flaws and limitations.

BibTeX @mastersthesis{Sparlund2017,author={Sparlund, Johan},title={Structural optimization of base engine component},abstract={The purpose of this thesis has been to investigate the potential implementation of structural optimization
software in the product development process at the department of engine development at Volvo Car
Corporation. This has been carried out by performing two trial cases of optimization on two different
base engine components. The models have been created in ANSA and solved with ABAQUS and
TOSCA.
The first trial case was of a simpler nature and involved a smaller component inside the bedplate. Its
purpose was mainly to bring knowledge about FE-modelling and optimization, which it fulfilled. The
second trial case was more complex, and aimed to find the optimal material distribution on the engine
block’s exterior surface in order to increase the first eigenfrequency of the component. It succeeded in
the sense that it increased the eigenfrequency, but the optimized topology does not contain rib-like
structures to a large extent, as was hoped. Rather, the majority of the element are spread thinly over
the entire surface.
The ultimate conclusion that can be drawn from the results is that it is complicated to implement the
use of structural optimization software on larger base engine components. Optimization is better suited
for more isolated components of smaller size, with a limited number of load cases that are clearly
defined. This would give the optimization solver a better chance to find an improved structure. It would
also limit the need for simplifications and therefore allow for greater confidence in the FE-model and
in turn the optimization results. The findings in this thesis does not completely reject the potential
implementation of structural optimization software in the product development phase, but does show
that structural optimization is not without its flaws and limitations.},publisher={Institutionen för tillämpad mekanik, Material- och beräkningsmekanik, Chalmers tekniska högskola},place={Göteborg},year={2017},series={Diploma work - Department of Applied Mechanics, Chalmers University of Technology, Göteborg, Sweden, no: 2017:36},}

RefWorks RT GenericSR ElectronicID 250339A1 Sparlund, JohanT1 Structural optimization of base engine componentT2 Structural optimization of base engine componentYR 2017AB The purpose of this thesis has been to investigate the potential implementation of structural optimization
software in the product development process at the department of engine development at Volvo Car
Corporation. This has been carried out by performing two trial cases of optimization on two different
base engine components. The models have been created in ANSA and solved with ABAQUS and
TOSCA.
The first trial case was of a simpler nature and involved a smaller component inside the bedplate. Its
purpose was mainly to bring knowledge about FE-modelling and optimization, which it fulfilled. The
second trial case was more complex, and aimed to find the optimal material distribution on the engine
block’s exterior surface in order to increase the first eigenfrequency of the component. It succeeded in
the sense that it increased the eigenfrequency, but the optimized topology does not contain rib-like
structures to a large extent, as was hoped. Rather, the majority of the element are spread thinly over
the entire surface.
The ultimate conclusion that can be drawn from the results is that it is complicated to implement the
use of structural optimization software on larger base engine components. Optimization is better suited
for more isolated components of smaller size, with a limited number of load cases that are clearly
defined. This would give the optimization solver a better chance to find an improved structure. It would
also limit the need for simplifications and therefore allow for greater confidence in the FE-model and
in turn the optimization results. The findings in this thesis does not completely reject the potential
implementation of structural optimization software in the product development phase, but does show
that structural optimization is not without its flaws and limitations.PB Institutionen för tillämpad mekanik, Material- och beräkningsmekanik, Chalmers tekniska högskola,T3 Diploma work - Department of Applied Mechanics, Chalmers University of Technology, Göteborg, Sweden, no: 2017:36LA engLK http://publications.lib.chalmers.se/records/fulltext/250339/250339.pdfOL 30